Microwave-based method and apparatus for monitoring a process variable

Abstract

The invention relates to apparatus for determining, online, characteristics of a process medium based on a novel open-ended microwave sensor configured to 5 operate about a fixed frequency band having a central frequency f0 with wavelength λ. The sensor further includes an impedance mismatch having a dimension related to λ.

Description

Field of the Invention

[0001] This invention relates to a microwave-based sensor for monitoring a process variable. By way of example only, embodiments of the invention may serve to monitor moisture content, sugar content and salt concentrationBackground to the Invention

[0002] There is a well-known and widespread requirement for devices that can detect changes in parameters of a medium, such parameters also known as a process 10 variables. In the context of this document the term process variable is intended to mean any variation in a physical parameter of a medium due to external effects and / or age. Particular process variables to which the invention has particular application include, but are not necessarily limited to, bulk density, moisture content, liquid concentration, sugar concentration, salt concentration and oil quality.

[0003] Current sensor technology includes infrared ray, ultrasonics, magnetic induction, Hall effect sensors and radio frequency-based devices. These technologies all have their place but many industrial processes require online monitoring of material parameters under high process temperatures and pressures. Under these conditions exiting technologies exhibit reliability problems.

[0004] Variations in complex permittivity of solid particles or liquids, using a radio-frequency open-ended coaxial sensor, is a popular means used to detect changes in material composition. US Patent 5,675,259 discloses a microwave probe based on a radio-frequency open-ended coaxial waveguide for monitoring the presence, concentration and flow in a flowline or in a holding container. The microwave sensor is designed for operating in a wide frequency band from zero to the upper limited frequency (f) using chosen waveguide diameters and selected insulation of particular permittivity, however the difference in reflected amplitude and phase is very small when the frequency is less than 1GHz, frequency being determined by the expression: f = c / π * √ ε * a + b where c is the speed of light in a vacuum; ε is the permittivity of the insulation material; a is the diameter of the centre conductor; and b is the inside diameter of the outer conductor. The probe in this example is designed to an impedance that is as constant as possible along the length of the probe, and in the order of 50 ohm.

[0005] US Patent 8,629,681 proposes a microwave sensor and algorithm to detect the bulk density and moisture content in granular or particulate material, especially agricultural commodities.

[0006] With existing forms of open-ended coaxial waveguide, the difference in reflected amplitudes from media with different complex permittivities is only about 4 - 6dB. As a result, high quality and costly electronic processing is required to distinguish reflected amplitudes and phase changes due to changes in media. When the permittivity of the medium is less than 5, it is challenging to implement an electronics circuitry and algorithm to effect reliable on-site differentiation.

[0007] A further factor requiring consideration is that traditional forms of open-ended coaxial sensors rely for their use on algorithms that derive material permittivity from the amplitude and phase of the return loss. The resulting permittivity is then used to monitor the change in material property. These algorithms require pre-calibration of the sensor using a number of different materials, each having known permittivity, so that some calibration constants can be determined. However, in subsequent use of the sensor, these constants are known sometimes to change with temperature and other variations in site condition, leading to errors in process control.

[0008] It is an object of the invention to provide a method and / or apparatus to check switch function that will go at least some way in addressing the aforementioned problems; or which will at least provide a novel and useful choice.

[0009] US 2015 / 276460 A1 relates to a coaxial feed-through device for coupling a received process connection to a storage tank including an inner electrical conductor, an outer electrical conductor; and a dielectric sleeve disposed between the probe and the outer electrical conductor. The dielectric sleeve is configured to provide an upper coaxial transmission line segment providing a substantially 50 ohm impedance and a lower coaxial transmission line segment which includes one or more sub-segments having an impedance that is at least forty percent higher as compared to the substantially 50 ohm impedance.

[0010] GB 2 527 794 A relates to a system and method that permits measuring properties and thickness of a dielectric layer, particularly a dielectric layer close to a pipeline wall, and more particularly fluids flowing inside a pipe is provided. The system comprises a sensor operating in a material characterization mode in a first frequency range and a sensor operating in a thickness characterization mode in a second frequency range.

[0011] EP 1 083 414 A1 relates to a level measuring instrument for measuring a level of a filled material in a container, in the case of which electromagnetic signals generated by means of an electronic circuit are guided into the container via a waveguide and signals reflected at a filled material surface are guided out, in the case of which an impedance-matching device active in a frequency band of a bandwidth is connected upstream of the waveguide. For this purpose, the level measuring instrument comprises an injector, which transmits the signals from the circuit to the waveguide, and which has an inner conductor, which inner conductor has, for the purpose of increasing the characteristic impedance, a conductor section with a geometry deviating from a cylindrical shape.Summary of the Invention

[0012] Accordingly, in a first aspect, the invention provides apparatus defined by claim 1.

[0013] Preferably said sensor includes a main waveguide section of impedance Z and wherein said impedance mismatch is at least 1.5Z and preferably substantially 4Z.

[0014] Preferably said impedance mismatch is effected by a resonant cavity located between said main waveguide section and said connection end.

[0015] Preferably said resonant cavity is evacuated, or filled with air or a low-permittivity foamed material.

[0016] Preferably said impedance mismatch has a dimension in the direction of length L of a multiple of substantially 1 / 4λ.

[0017] Preferably said main waveguide section has a dimension in the direction of L which is a multiple of substantially 1 / 4 λ.

[0018] Preferably said apparatus further includes an expansion section formed at said distal end in which said inner electrode is expanded in diameter and said outer electrode is reduced in thickness to accommodate the expansion.

[0019] Preferably the dimension of said expansion section in the direction of L is a multiple of substantially 1 / 4 λ.

[0020] Preferably an insulating coating is provided over said distal end to prevent short-circuiting between said inner and outer conductors.

[0021] Preferably the electrical insulation between said outer and inner electrodes comprises a thermal insulating material.

[0022] Preferably said sensor further includes a thermal insulation section at the connection end thereof.

[0023] Preferably said processing electronics is configured to initiate an output derived solely from amplitudes of return loss.

[0024] Alternatively said processing electronics is configured to initiate an output derived from amplitude and phase changes of return loss.

[0025] Preferably said processing electronics is configured to apply a peak fitting algorithm to peaks of return loss, to then determine changes of amplitude and / or bandwidth at those peaks of return loss, and thereby provide an indication of change in process variable.

[0026] In a second aspect the invention provides apparatus operable to monitor a change in process variable in a medium, said apparatus including a microwave sensor configured and arranged to interact with the medium, and drive and processing electronics configured and operable to provide drive signals to said sensor, to receive and process received signals from said sensor, and to initiate an output, wherein said sensor comprises an open ended microwave waveguide formed by an outer electrode and an inner electrode held co-axially within said outer electrode with electrical insulation there-between, said sensor having a connection end for connection to said processing electronics, a distal end for mounting in substantial contact with a wall of a non-conductive vessel containing said medium or in substantial contact with a non-conductive window in a wall of a vessel containing said medium, said sensor having a length L and wherein said sensor is configured to operate within a frequency band having a frequency f 0 with wavelength λ located substantially centrally within said band, said sensor including at least one impedance mismatch having a dimension in the direction of length L related to λ and wherein said process electronics is configured to initiate an output derived from amplitudes of return loss.

[0027] Preferably said apparatus includes one or more features as set forth above.

[0028] Many variations in the way the present invention can be performed will present themselves to those skilled in the art. The description which follows is intended as an illustration only of one means of performing the invention and Subject to the scope of the appended claims, the lack of description of variants or equivalents should not be regarded as limiting.Brief Description of the Drawings

[0029] One working embodiment of the invention will now be described with reference to the accompanying drawings in which: Figure 1:shows a cross-section through a prior art open-ended waveguide sensor; Figure 2:shows a cross-section through an open-ended waveguide sensor according to the invention; Figure 3:shows simulated comparisons of amplitudes of return losses of a sensor according to the invention, and a prior art sensor, respectively operating in media of differing permittivities; Figure 4:shows plots of return losses derived from samples of basmati rice of differing moisture contents; Figure 5:shows plots of resonant frequency change derived by applying curve fitting to the data shown in Figure 4; Figure 6:shows plots of bandwidth change derived by applying curve fitting to the data shown in Figure 4; Figure 7:shows an example of drive and processing circuit which may be used to implement the invention; and Figure 8:shows a curve fitting technique used in the derivation of Figures 5 & 6 Detailed Description of Working Embodiment

[0030] Referring firstly to Fig 1, a typical prior art open-ended waveguide sensor 10 is shown in Figure 1 but reference can also be made to US Patent 5,675,259 which contains a detailed description of the construction and operation of such a sensor as well as various industrial applications in which a sensor of this type can be used. In the form shown in Fig 1, the sensor 10 has a connection end 11 and a distal end 12 for contact with a fluid which, in the context of this disclosure, includes gases, liquids and fine solids such as powders. The sensor 10 includes an inner electrode 13, an outer electrode 14, the electrodes 13 and 14 held in spaced relationship (typically co-axial relationship) by an electrically insulating material 15. The electrodes are typically formed from a 20 metal such as stainless steel and the insulating material 15 may comprise a suitable plastics material such as polytetrafluoroethylene (PTFE), or a suitable ceramic.

[0031] The outer electrode 14 may comprise the outer body of the sensor which, in the form shown, includes a threaded section 16 to allow the sensor to be mounted in the position in which it is to be used. Typically this will be an aperture of a relatively restricted diameter in the wall of a process vessel.

[0032] The sensor shown in Fig 1 is configured according to design rules which dictate that the impedance of the sensor should be kept as constant as possible along its length and that the sensor should operate over a wide frequency band with the highest possible cut-off frequency; that is to say the highest frequency to maintain transverse electromagnetic (TEM) mode. As will become apparent from the description that follows, this limits the usefulness of such a sensor forming part of an instrument for monitoring process variables.

[0033] Turning now to Fig 2, an open-ended wave-guide sensor 20 incorporated in a level switch according to the invention is configured to different design rules, namely: i) The sensor should be optimized around a central working frequency f 0 with wavelength λ; ii) the sensor should include a high impedance section having a dimension along the length of the sensor that is a multiple of ¼ λ; iii) the lengths of the various sections of the sensor should be multiples of 1 4 λ; iv) the ratio of diameters of the inner and outer electrodes should be chosen to provide a cut-off frequency that is as high as possible above f 0 ; and v) the lateral dimension of the sensor at the distal end should be expanded to improve the sensitivity of the sensor to media of low permittivity.

[0034] The sensor 20 has a connection end 21 for connection to drive and processing electronics, a distal end 22 for contact with the media, an inner electrode 23 and an outer electrode 24, the electrodes 23 and 24 being separated by an insulator 25. As with the prior art sensor the electrodes may be formed from stainless steel and the insulator 25 from PTFE, ceramic or other suitable material. For higher temperature applications it is preferred to form the electrodes from titanium, in which case the insulation should be of material having a very similar thermal expansion coefficient. An example of such a material is Ceramit ®< 14, a material available from Ceramic Substrates and Components Limited of Newport, Isle of Wight, UK.

[0035] It should be emphasised that other materials may be used and that the scope of the invention is not to be limited to particular combinations of electrode material and insulation composition.

[0036] The sensor 20 is comprised of a number of different sections arranged along length L and configured to significantly improve performance over the prior art sensors mentioned. At or adjacent to connection end 20 is a reflection section in the form of resonant cavity 26 that provides an impedance mismatch. The sensor further includes a main waveguide section 27, and a tip 15 section 28. As can be seen, the tip section 28 is preferably domed in shape by projecting the inner electrode 23 out beyond the outer electrode 24 at 29 by an amount of around 1 10 λ or less, and forming the insulation between the electrodes to encourage liquids to drop off the distal end 22 of the sensor, the tip section preferably being provided with a thin coating of a suitable polymer 20 such as, for example, polyfluorenylene ethynylene (PFE), or in high temperature applications, a thin layer of Ceramit 14.

[0037] For applications in which high temperatures are anticipated, the connection end may be provided with a thermal insulation section 30 formed with a glassmetal seal to reduce bring down the temperature from the working parts of the 25 sensor before the sensor is connected to the drive and processing facility.

[0038] The reflection section or resonant cavity 26 is configured to generate a resonant standing wave around the frequency f 0 in the main sensor body through a significant impedance change or mismatch, the impedance of this section being at least 1 1 2 times that of the main waveguide and more preferably 3 to 4 times the impedance of the main waveguide section. The impedance mismatch may be achieved by evacuating the cavity or filling it with air or a low permittivity material such as foam, examples of which include a low dielectric open cell foam such as, for example, Cuming Microwave C-Stock or Eccostock FFP. The length dimension of the section 26 is preferably a multiple of ¼λ.

[0039] As indicated in Fig 2, the thermal insulation section 30, reflection section 26, main waveguide section 27, tip section 28, and domed end 29 have dimensions X 1 , X 2 , X 3 , X 4 and X 5 respectively in the direction of L. Performance of the sensor is enhanced if X 2 is a multiple of ¼λ while X 3 , and X 4 are multiples of ½λ. X 5 is preferably in the order of 1 10 λ.

[0040] In order to achieve a distinguishable difference in reflected amplitude and preferably phase induced by a permittivity change of the process media, especially media with a permittivity in the range of about 2 - 3, the performance of the proposed sensor has been optimised in a narrow frequency band to its centre frequency f 0 , say 4.5GHz, or to its resonant frequency of 3.2GHz or 5.7GHz.

[0041] The resonant cavity 26 has more than at least 1.5 times the impedance of the main co-axial waveguide section and preferably in the order of four times the impedance. The resonant cavity is conveniently formed by altering the conductor or electrode dimensions and changing the insulating properties. The length of the resonant cavity is preferably a multiple of a quarter of the wavelength of the centre working frequency.

[0042] By way of example only, a sensor configured for mounting through an industry-standard 1'' diameter mounting hole may have an effective 24 mm outer diameter, a maximum internal diameter of 20 mm, titanium electrodes and Ceramit 14 insulation and may be configured such that the various sections have the following dimensions: Sectiona (mm)b (mm)εf (GHz)Z (ohm)Thermal Insulation715.210.551.2Reflection Section221.518.161.1Main waveguide725.24.931.0Expansion section2475.22.732.4

[0043] Where a is the outside diameter of the insulation, b is the outside diameter of 10 the inner conductor, ε is permittivity, f is cut-off frequency and Z is impedance.

[0044] A simulated comparison of the performance of the sensor proposed herein, with a prior art sensor of the type described in US patent 5,675,259 is shown in Figure 3 and it can be seen that the S11 return losses at different permittivities using the proposed sensor occur at clearly defined frequencies when compared with the same return losses measured with the prior art sensor. As is well known by those skilled in the art, when a transverse electromagnetic wave (TEM) is transmitted along the sensor body and reflected at the distal end 22, the amplitude and phase of the reflected wave will vary depending on the permittivity of the medium surrounding the distal end 22. As described above prior art instruments used in monitoring process variables have first determined the change in permittivity and, from that, determined the change in process variable. The present invention provides a combination of novel sensor and algorithm that allows differences 25 in variable to be established directly from the amplitudes of return losses while at the same time allowing the use of phase information to be included in the calculation, if desired.

[0045] Referring now to Figures 4 to 6, an example is shown of the invention being applied to the determination of moisture content in basmati rice. Figure 4 shows plots of amplitudes of return loss against frequency, which are established before installation of the sensor by direct measurements taken using samples of basmati rice having different levels of moisture content. It can be seen that for each moisture level the amplitude of the return loss reaches a clearly defined minimum peak at a clearly defined frequency. By applying a typical Gaussian peak fitting to each negative peak, two relationships can be established, the first being a 2 nd< order polynomial plot of resonant frequency against moisture content as shown in Figure 5, and the second being a linear plot of bandwidth against moisture content as shown in Figure 6. Once the relationship of resonant frequency or bandwidth has been established by the polynomial fitting formulae, any moisture content between 0% and 23% can be derived by direct measurement of resonant frequency and / or bandwidth.

[0046] To improve the accuracy of moisture measurement with change in resonant frequency, the curve-fitting algorithm is designed to draw peak and bandwidth information from a number of measurement points around the peak resonant frequency. An example of the procedure adopted is: i) Data points are chosen around the resonant frequency peak to a level around 4dB above the dip point of S11 as shown in the block in Figure 8; ii) The curve fitting algorithm Gaussian peak fitting algorithm is then applied to find coefficients a1, b1 & c1 in the equation: iii) Calculate the peak frequency from the fitted curve, f peak = b1; iv) Calculate the -3dB full bandwidth from the fitted curve, BW = 1.665* cl

[0047] Either peak or bandwidth will vary with changes in material parameter e.g. moisture content as permittivity changes. These changes can be used to characterize the parameter of the material, in this case moisture content, on site from the plots shown in Figures 5 and 6.

[0048] Note that by only using amplitude information, a full calibration over a range of permittivities for each material is not required and the system constants are 10 not sensitive to the conditions in which the sensor is operating. Shifts in resonant frequency are proportional to changes in the real part of permittivity whereas the changes in bandwidth are proportional to the imaginary part of permittivity.

[0049] This also leads to a simplified radio frequency (RF) drive and processing circuit in which the need for an RF frequency mixer and I / Q modulation means can be eliminated if phase information is not required for the determination of material characteristic. An example of circuit which can be used to implement the invention is shown in Figure 7.

[0050] As shown in Figure 7, microcontroller 32 sends a signal to voltage-controlled 20 oscillator 33 to start frequency sweeping in pre-determined frequency steps within a frequency band. The resulting RF signals are directed to directional coupler 34 in which they are split into two parts in a known ratio, one part going directly to sensor 35 to be reflected back when it meets the distal end of the sensor in contact with, or adjacent to, the medium under observation. The 25 other part of the RF signal is directed to RF power switch 36 as a reference signal to the sensor. Through operation of switch 36 the reference and reflected signals are directed in turn to RF power detector 37, analogue to digital convertor 38 and then to the microcontroller 32. The microcontroller 32 then calculates the power ratio between reflected and reference signals as the amplitude of return loss S11 for each frequency step.

[0051] It thus follows that the circuit described is a calibration-free return loss amplitude measurement circuit.

[0052] Whilst the above description may be interpreted as applying to apparatus mounted through an aperture in a process vessel, the invention may also be applied to apparatus mounted in a non-penetrating manner on the outer surface 10 of a vessel which is formed from a non-conducting material such as, for example, plastic, glass or ceramic; or mounted on a non-conducting window included in the wall of a vessel otherwise formed from a conducting material. In such situations a lower design frequency f 0 , say around 3.5GHz is preferred as it will allow the microwave energy to penetrate the container wall and generate a large effective sensing volume more easily.

Examples

Embodiment Construction

[0030]Referring firstly to Fig 1, a typical prior art open-ended waveguide sensor 10 is shown in Figure 1 but reference can also be made to US Patent 5,675,259 which contains a detailed description of the construction and operation of such a sensor as well as various industrial applications in which a sensor of this type can be used. In the form shown in Fig 1, the sensor 10 has a connection end 11 and a distal end 12 for contact with a fluid which, in the context of this disclosure, includes gases, liquids and fine solids such as powders. The sensor 10 includes an inner electrode 13, an outer electrode 14, the electrodes 13 and 14 held in spaced relationship (typically co-axial relationship) by an electrically insulating material 15. The electrodes are typically formed from a 20 metal such as stainless steel and the insulating material 15 may comprise a suitable plastics material such as polytetrafluoroethylene (PTFE), or a suitable ceramic.

[0031]The outer electrode 14 may compri...

Field of the Invention

[0001] This invention relates to a microwave-based sensor for monitoring a process variable. By way of example only, embodiments of the invention may serve to monitor moisture content, sugar content and salt concentrationBackground to the Invention

[0002] There is a well-known and widespread requirement for devices that can detect changes in parameters of a medium, such parameters also known as a process 10 variables. In the context of this document the term process variable is intended to mean any variation in a physical parameter of a medium due to external effects and / or age. Particular process variables to which the invention has particular application include, but are not necessarily limited to, bulk density, moisture content, liquid concentration, sugar concentration, salt concentration and oil quality.

[0003] Current sensor technology includes infrared ray, ultrasonics, magnetic induction, Hall effect sensors and radio frequency-based devices. These technologies all have their place but many industrial processes require online monitoring of material parameters under high process temperatures and pressures. Under these conditions exiting technologies exhibit reliability problems.

[0004] Variations in complex permittivity of solid particles or liquids, using a radio-frequency open-ended coaxial sensor, is a popular means used to detect changes in material composition. US Patent 5,675,259 discloses a microwave probe based on a radio-frequency open-ended coaxial waveguide for monitoring the presence, concentration and flow in a flowline or in a holding container. The microwave sensor is designed for operating in a wide frequency band from zero to the upper limited frequency (f) using chosen waveguide diameters and selected insulation of particular permittivity, however the difference in reflected amplitude and phase is very small when the frequency is less than 1GHz, frequency being determined by the expression: f = c / π * √ ε * a + b where c is the speed of light in a vacuum; ε is the permittivity of the insulation material; a is the diameter of the centre conductor; and b is the inside diameter of the outer conductor. The probe in this example is designed to an impedance that is as constant as possible along the length of the probe, and in the order of 50 ohm.

[0005] US Patent 8,629,681 proposes a microwave sensor and algorithm to detect the bulk density and moisture content in granular or particulate material, especially agricultural commodities.

[0006] With existing forms of open-ended coaxial waveguide, the difference in reflected amplitudes from media with different complex permittivities is only about 4 - 6dB. As a result, high quality and costly electronic processing is required to distinguish reflected amplitudes and phase changes due to changes in media. When the permittivity of the medium is less than 5, it is challenging to implement an electronics circuitry and algorithm to effect reliable on-site differentiation.

[0007] A further factor requiring consideration is that traditional forms of open-ended coaxial sensors rely for their use on algorithms that derive material permittivity from the amplitude and phase of the return loss. The resulting permittivity is then used to monitor the change in material property. These algorithms require pre-calibration of the sensor using a number of different materials, each having known permittivity, so that some calibration constants can be determined. However, in subsequent use of the sensor, these constants are known sometimes to change with temperature and other variations in site condition, leading to errors in process control.

[0008] It is an object of the invention to provide a method and / or apparatus to check switch function that will go at least some way in addressing the aforementioned problems; or which will at least provide a novel and useful choice.

[0009] US 2015 / 276460 A1 relates to a coaxial feed-through device for coupling a received process connection to a storage tank including an inner electrical conductor, an outer electrical conductor; and a dielectric sleeve disposed between the probe and the outer electrical conductor. The dielectric sleeve is configured to provide an upper coaxial transmission line segment providing a substantially 50 ohm impedance and a lower coaxial transmission line segment which includes one or more sub-segments having an impedance that is at least forty percent higher as compared to the substantially 50 ohm impedance.

[0010] GB 2 527 794 A relates to a system and method that permits measuring properties and thickness of a dielectric layer, particularly a dielectric layer close to a pipeline wall, and more particularly fluids flowing inside a pipe is provided. The system comprises a sensor operating in a material characterization mode in a first frequency range and a sensor operating in a thickness characterization mode in a second frequency range.

[0011] EP 1 083 414 A1 relates to a level measuring instrument for measuring a level of a filled material in a container, in the case of which electromagnetic signals generated by means of an electronic circuit are guided into the container via a waveguide and signals reflected at a filled material surface are guided out, in the case of which an impedance-matching device active in a frequency band of a bandwidth is connected upstream of the waveguide. For this purpose, the level measuring instrument comprises an injector, which transmits the signals from the circuit to the waveguide, and which has an inner conductor, which inner conductor has, for the purpose of increasing the characteristic impedance, a conductor section with a geometry deviating from a cylindrical shape.Summary of the Invention

[0012] Accordingly, in a first aspect, the invention provides apparatus defined by claim 1.

[0013] Preferably said sensor includes a main waveguide section of impedance Z and wherein said impedance mismatch is at least 1.5Z and preferably substantially 4Z.

[0014] Preferably said impedance mismatch is effected by a resonant cavity located between said main waveguide section and said connection end.

[0015] Preferably said resonant cavity is evacuated, or filled with air or a low-permittivity foamed material.

[0016] Preferably said impedance mismatch has a dimension in the direction of length L of a multiple of substantially 1 / 4λ.

[0017] Preferably said main waveguide section has a dimension in the direction of L which is a multiple of substantially 1 / 4 λ.

[0018] Preferably said apparatus further includes an expansion section formed at said distal end in which said inner electrode is expanded in diameter and said outer electrode is reduced in thickness to accommodate the expansion.

[0019] Preferably the dimension of said expansion section in the direction of L is a multiple of substantially 1 / 4 λ.

[0020] Preferably an insulating coating is provided over said distal end to prevent short-circuiting between said inner and outer conductors.

[0021] Preferably the electrical insulation between said outer and inner electrodes comprises a thermal insulating material.

[0022] Preferably said sensor further includes a thermal insulation section at the connection end thereof.

[0023] Preferably said processing electronics is configured to initiate an output derived solely from amplitudes of return loss.

[0024] Alternatively said processing electronics is configured to initiate an output derived from amplitude and phase changes of return loss.

[0025] Preferably said processing electronics is configured to apply a peak fitting algorithm to peaks of return loss, to then determine changes of amplitude and / or bandwidth at those peaks of return loss, and thereby provide an indication of change in process variable.

[0026] In a second aspect the invention provides apparatus operable to monitor a change in process variable in a medium, said apparatus including a microwave sensor configured and arranged to interact with the medium, and drive and processing electronics configured and operable to provide drive signals to said sensor, to receive and process received signals from said sensor, and to initiate an output, wherein said sensor comprises an open ended microwave waveguide formed by an outer electrode and an inner electrode held co-axially within said outer electrode with electrical insulation there-between, said sensor having a connection end for connection to said processing electronics, a distal end for mounting in substantial contact with a wall of a non-conductive vessel containing said medium or in substantial contact with a non-conductive window in a wall of a vessel containing said medium, said sensor having a length L and wherein said sensor is configured to operate within a frequency band having a frequency f 0 with wavelength λ located substantially centrally within said band, said sensor including at least one impedance mismatch having a dimension in the direction of length L related to λ and wherein said process electronics is configured to initiate an output derived from amplitudes of return loss.

[0027] Preferably said apparatus includes one or more features as set forth above.

[0028] Many variations in the way the present invention can be performed will present themselves to those skilled in the art. The description which follows is intended as an illustration only of one means of performing the invention and Subject to the scope of the appended claims, the lack of description of variants or equivalents should not be regarded as limiting.Brief Description of the Drawings

[0029] One working embodiment of the invention will now be described with reference to the accompanying drawings in which: Figure 1:shows a cross-section through a prior art open-ended waveguide sensor; Figure 2:shows a cross-section through an open-ended waveguide sensor according to the invention; Figure 3:shows simulated comparisons of amplitudes of return losses of a sensor according to the invention, and a prior art sensor, respectively operating in media of differing permittivities; Figure 4:shows plots of return losses derived from samples of basmati rice of differing moisture contents; Figure 5:shows plots of resonant frequency change derived by applying curve fitting to the data shown in Figure 4; Figure 6:shows plots of bandwidth change derived by applying curve fitting to the data shown in Figure 4; Figure 7:shows an example of drive and processing circuit which may be used to implement the invention; and Figure 8:shows a curve fitting technique used in the derivation of Figures 5 & 6 Detailed Description of Working Embodiment

[0030] Referring firstly to Fig 1, a typical prior art open-ended waveguide sensor 10 is shown in Figure 1 but reference can also be made to US Patent 5,675,259 which contains a detailed description of the construction and operation of such a sensor as well as various industrial applications in which a sensor of this type can be used. In the form shown in Fig 1, the sensor 10 has a connection end 11 and a distal end 12 for contact with a fluid which, in the context of this disclosure, includes gases, liquids and fine solids such as powders. The sensor 10 includes an inner electrode 13, an outer electrode 14, the electrodes 13 and 14 held in spaced relationship (typically co-axial relationship) by an electrically insulating material 15. The electrodes are typically formed from a 20 metal such as stainless steel and the insulating material 15 may comprise a suitable plastics material such as polytetrafluoroethylene (PTFE), or a suitable ceramic.

[0031] The outer electrode 14 may comprise the outer body of the sensor which, in the form shown, includes a threaded section 16 to allow the sensor to be mounted in the position in which it is to be used. Typically this will be an aperture of a relatively restricted diameter in the wall of a process vessel.

[0032] The sensor shown in Fig 1 is configured according to design rules which dictate that the impedance of the sensor should be kept as constant as possible along its length and that the sensor should operate over a wide frequency band with the highest possible cut-off frequency; that is to say the highest frequency to maintain transverse electromagnetic (TEM) mode. As will become apparent from the description that follows, this limits the usefulness of such a sensor forming part of an instrument for monitoring process variables.

[0033] Turning now to Fig 2, an open-ended wave-guide sensor 20 incorporated in a level switch according to the invention is configured to different design rules, namely: i) The sensor should be optimized around a central working frequency f 0 with wavelength λ; ii) the sensor should include a high impedance section having a dimension along the length of the sensor that is a multiple of ¼ λ; iii) the lengths of the various sections of the sensor should be multiples of 1 4 λ; iv) the ratio of diameters of the inner and outer electrodes should be chosen to provide a cut-off frequency that is as high as possible above f 0 ; and v) the lateral dimension of the sensor at the distal end should be expanded to improve the sensitivity of the sensor to media of low permittivity.

[0034] The sensor 20 has a connection end 21 for connection to drive and processing electronics, a distal end 22 for contact with the media, an inner electrode 23 and an outer electrode 24, the electrodes 23 and 24 being separated by an insulator 25. As with the prior art sensor the electrodes may be formed from stainless steel and the insulator 25 from PTFE, ceramic or other suitable material. For higher temperature applications it is preferred to form the electrodes from titanium, in which case the insulation should be of material having a very similar thermal expansion coefficient. An example of such a material is Ceramit ®< 14, a material available from Ceramic Substrates and Components Limited of Newport, Isle of Wight, UK.

[0035] It should be emphasised that other materials may be used and that the scope of the invention is not to be limited to particular combinations of electrode material and insulation composition.

[0036] The sensor 20 is comprised of a number of different sections arranged along length L and configured to significantly improve performance over the prior art sensors mentioned. At or adjacent to connection end 20 is a reflection section in the form of resonant cavity 26 that provides an impedance mismatch. The sensor further includes a main waveguide section 27, and a tip 15 section 28. As can be seen, the tip section 28 is preferably domed in shape by projecting the inner electrode 23 out beyond the outer electrode 24 at 29 by an amount of around 1 10 λ or less, and forming the insulation between the electrodes to encourage liquids to drop off the distal end 22 of the sensor, the tip section preferably being provided with a thin coating of a suitable polymer 20 such as, for example, polyfluorenylene ethynylene (PFE), or in high temperature applications, a thin layer of Ceramit 14.

[0037] For applications in which high temperatures are anticipated, the connection end may be provided with a thermal insulation section 30 formed with a glassmetal seal to reduce bring down the temperature from the working parts of the 25 sensor before the sensor is connected to the drive and processing facility.

[0038] The reflection section or resonant cavity 26 is configured to generate a resonant standing wave around the frequency f 0 in the main sensor body through a significant impedance change or mismatch, the impedance of this section being at least 1 1 2 times that of the main waveguide and more preferably 3 to 4 times the impedance of the main waveguide section. The impedance mismatch may be achieved by evacuating the cavity or filling it with air or a low permittivity material such as foam, examples of which include a low dielectric open cell foam such as, for example, Cuming Microwave C-Stock or Eccostock FFP. The length dimension of the section 26 is preferably a multiple of ¼λ.

[0039] As indicated in Fig 2, the thermal insulation section 30, reflection section 26, main waveguide section 27, tip section 28, and domed end 29 have dimensions X 1 , X 2 , X 3 , X 4 and X 5 respectively in the direction of L. Performance of the sensor is enhanced if X 2 is a multiple of ¼λ while X 3 , and X 4 are multiples of ½λ. X 5 is preferably in the order of 1 10 λ.

[0040] In order to achieve a distinguishable difference in reflected amplitude and preferably phase induced by a permittivity change of the process media, especially media with a permittivity in the range of about 2 - 3, the performance of the proposed sensor has been optimised in a narrow frequency band to its centre frequency f 0 , say 4.5GHz, or to its resonant frequency of 3.2GHz or 5.7GHz.

[0041] The resonant cavity 26 has more than at least 1.5 times the impedance of the main co-axial waveguide section and preferably in the order of four times the impedance. The resonant cavity is conveniently formed by altering the conductor or electrode dimensions and changing the insulating properties. The length of the resonant cavity is preferably a multiple of a quarter of the wavelength of the centre working frequency.

[0042] By way of example only, a sensor configured for mounting through an industry-standard 1'' diameter mounting hole may have an effective 24 mm outer diameter, a maximum internal diameter of 20 mm, titanium electrodes and Ceramit 14 insulation and may be configured such that the various sections have the following dimensions: Sectiona (mm)b (mm)εf (GHz)Z (ohm)Thermal Insulation715.210.551.2Reflection Section221.518.161.1Main waveguide725.24.931.0Expansion section2475.22.732.4

[0043] Where a is the outside diameter of the insulation, b is the outside diameter of 10 the inner conductor, ε is permittivity, f is cut-off frequency and Z is impedance.

[0044] A simulated comparison of the performance of the sensor proposed herein, with a prior art sensor of the type described in US patent 5,675,259 is shown in Figure 3 and it can be seen that the S11 return losses at different permittivities using the proposed sensor occur at clearly defined frequencies when compared with the same return losses measured with the prior art sensor. As is well known by those skilled in the art, when a transverse electromagnetic wave (TEM) is transmitted along the sensor body and reflected at the distal end 22, the amplitude and phase of the reflected wave will vary depending on the permittivity of the medium surrounding the distal end 22. As described above prior art instruments used in monitoring process variables have first determined the change in permittivity and, from that, determined the change in process variable. The present invention provides a combination of novel sensor and algorithm that allows differences 25 in variable to be established directly from the amplitudes of return losses while at the same time allowing the use of phase information to be included in the calculation, if desired.

[0045] Referring now to Figures 4 to 6, an example is shown of the invention being applied to the determination of moisture content in basmati rice. Figure 4 shows plots of amplitudes of return loss against frequency, which are established before installation of the sensor by direct measurements taken using samples of basmati rice having different levels of moisture content. It can be seen that for each moisture level the amplitude of the return loss reaches a clearly defined minimum peak at a clearly defined frequency. By applying a typical Gaussian peak fitting to each negative peak, two relationships can be established, the first being a 2 nd< order polynomial plot of resonant frequency against moisture content as shown in Figure 5, and the second being a linear plot of bandwidth against moisture content as shown in Figure 6. Once the relationship of resonant frequency or bandwidth has been established by the polynomial fitting formulae, any moisture content between 0% and 23% can be derived by direct measurement of resonant frequency and / or bandwidth.

[0046] To improve the accuracy of moisture measurement with change in resonant frequency, the curve-fitting algorithm is designed to draw peak and bandwidth information from a number of measurement points around the peak resonant frequency. An example of the procedure adopted is: i) Data points are chosen around the resonant frequency peak to a level around 4dB above the dip point of S11 as shown in the block in Figure 8; ii) The curve fitting algorithm Gaussian peak fitting algorithm is then applied to find coefficients a1, b1 & c1 in the equation: iii) Calculate the peak frequency from the fitted curve, f peak = b1; iv) Calculate the -3dB full bandwidth from the fitted curve, BW = 1.665* cl

[0047] Either peak or bandwidth will vary with changes in material parameter e.g. moisture content as permittivity changes. These changes can be used to characterize the parameter of the material, in this case moisture content, on site from the plots shown in Figures 5 and 6.

[0048] Note that by only using amplitude information, a full calibration over a range of permittivities for each material is not required and the system constants are 10 not sensitive to the conditions in which the sensor is operating. Shifts in resonant frequency are proportional to changes in the real part of permittivity whereas the changes in bandwidth are proportional to the imaginary part of permittivity.

[0049] This also leads to a simplified radio frequency (RF) drive and processing circuit in which the need for an RF frequency mixer and I / Q modulation means can be eliminated if phase information is not required for the determination of material characteristic. An example of circuit which can be used to implement the invention is shown in Figure 7.

[0050] As shown in Figure 7, microcontroller 32 sends a signal to voltage-controlled 20 oscillator 33 to start frequency sweeping in pre-determined frequency steps within a frequency band. The resulting RF signals are directed to directional coupler 34 in which they are split into two parts in a known ratio, one part going directly to sensor 35 to be reflected back when it meets the distal end of the sensor in contact with, or adjacent to, the medium under observation. The 25 other part of the RF signal is directed to RF power switch 36 as a reference signal to the sensor. Through operation of switch 36 the reference and reflected signals are directed in turn to RF power detector 37, analogue to digital convertor 38 and then to the microcontroller 32. The microcontroller 32 then calculates the power ratio between reflected and reference signals as the amplitude of return loss S11 for each frequency step.

[0051] It thus follows that the circuit described is a calibration-free return loss amplitude measurement circuit.

[0052] Whilst the above description may be interpreted as applying to apparatus mounted through an aperture in a process vessel, the invention may also be applied to apparatus mounted in a non-penetrating manner on the outer surface 10 of a vessel which is formed from a non-conducting material such as, for example, plastic, glass or ceramic; or mounted on a non-conducting window included in the wall of a vessel otherwise formed from a conducting material. In such situations a lower design frequency f 0 , say around 3.5GHz is preferred as it will allow the microwave energy to penetrate the container wall and generate a large effective sensing volume more easily.

Examples

Embodiment Construction

[0030]Referring firstly to Fig 1, a typical prior art open-ended waveguide sensor 10 is shown in Figure 1 but reference can also be made to US Patent 5,675,259 which contains a detailed description of the construction and operation of such a sensor as well as various industrial applications in which a sensor of this type can be used. In the form shown in Fig 1, the sensor 10 has a connection end 11 and a distal end 12 for contact with a fluid which, in the context of this disclosure, includes gases, liquids and fine solids such as powders. The sensor 10 includes an inner electrode 13, an outer electrode 14, the electrodes 13 and 14 held in spaced relationship (typically co-axial relationship) by an electrically insulating material 15. The electrodes are typically formed from a 20 metal such as stainless steel and the insulating material 15 may comprise a suitable plastics material such as polytetrafluoroethylene (PTFE), or a suitable ceramic.

[0031]The outer electrode 14 may compri...

Claims

1. Apparatus operable to monitor a change in process variable in a medium in contact with said apparatus, said apparatus including: a microwave sensor having a connection end (21) and a distal end (22) for contact with the medium; and drive and processing electronics connected to the connection end (21) of the microwave sensor and configured and operable to provide drive signals to the connection end (21) of said sensor, to receive and process received signals resulting from reflection of the drive signals at the distal end (22) of said sensor, and to initiate an output, wherein said sensor comprises an open ended microwave waveguide formed by an outer electrode (24) and an inner electrode (23) held co-axially within said outer electrode (24) with electrical insulation (25) there-between, said sensor having a length L, wherein said sensor is configured to operate within a frequency band having a frequency f0 with wavelength λ located substantially centrally within said band, said sensor including at least one impedance mismatch having a dimension in the direction of length L related to λ, characterized by that at said distal end (22), said inner electrode (23) projects beyond said outer electrode (24) in the direction of L by an amount of around 1 / 10λ or less, and wherein said process electronics is configured to initiate an output derived from amplitudes of return loss of the received signals in relation to the drive signals.

2. Apparatus as claimed in claim 1 wherein said sensor includes a main waveguide section (27) of impedance Z and wherein said impedance mismatch is least 1.5Z and preferably substantially 4Z.

3. Apparatus as claimed in claim 2 wherein said impedance mismatch is effected by a resonant cavity (26) located between said main waveguide (27) section and said connection end (21).

4. Apparatus as claimed in claim 2 or claim 3 wherein said resonant cavity (26) is evacuated, or filled with air or a low-permittivity foamed material.

5. Apparatus as claimed in any one of claims 1 to 4 wherein said impedance mismatch has a dimension in the direction of length L of a multiple of substantially 1 / 4λ.

6. Apparatus as claimed in any one of claims 2 to 5 wherein said main waveguide section (27) has a dimension in the direction of L which is a multiple of substantially 1 / 4λ.

7. Apparatus as claimed in any one of the preceding claims further including an expansion section (28) formed at said distal end (22) in which said inner electrode (23) is expanded in diameter and said outer electrode (24) is reduced in thickness to accommodate the expansion.

8. Apparatus as claimed in claim 7 wherein the dimension of said expansion section (28) in the direction of L is a multiple of substantially 1 / 4λ.

9. Apparatus as claimed in any one of the preceding claims wherein an insulating coating is provided over said distal end (28) to prevent short-circuiting between said inner (23) and outer (24) conductors.

10. Apparatus as claimed in any one of the preceding claims wherein the electrical insulation (25) between said outer (24) and inner (23) electrodes comprises a thermal insulating material.

11. Apparatus as claimed in any one of the preceding claims wherein said sensor further includes a thermal insulation section (30) at the connection end (21) thereof.

12. Apparatus as claimed in any one of the preceding claims wherein said processing electronics is configured to initiate an output derived solely from amplitudes of return loss.

13. Apparatus as claimed in any one of claims 1 to 11 wherein said processing electronics is configured to initiate an output derived from amplitude and phase changes of return loss.

14. Apparatus as claimed in any one of the preceding claims wherein said processing electronics is configured to apply a peak fitting algorithm to peaks of return loss, to then determine changes of amplitude and / or bandwidth at those peaks of return loss, and thereby provide an indication of change in process variable.

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